IN Lately I was very interested in cutting out with a jigsaw, I don’t even know why it would be. It all started with the fact that I needed to cut a few gears out of plywood...
And off we go. At first I sawed the gears by hand, then I thought, pumping a muscle with a manual jigsaw is certainly good, but if you automate the process, it will be much faster!
So, for starters, get acquainted, this is a manual jigsaw for artistic sawing.
(all photos in this article were found on the Internet)
To cut, you need files, they are thin like wire, with sharp teeth. Previously, such files were sold in a pack of 50 pieces. Recently I went to the store, so these "bimesmen" began to sell them individually. During the evening, you can break a couple of pieces of such files.
For sawing, we also need a special table, it can be a board with a conical slot, screwed to the table with screws or a clamp.
For the convenience of attaching files to the machine, it is better to use a special device that will compress the contour of the jigsaw, so you can easily change the file without effort. With the help of a wooden eccentric, compression occurs.
And now about automation. In the next photo you see desktop jigsaw factory type, on the Internet you can find a sea of \u200b\u200bdifferent modifications. This thing is not very expensive, but even if I really want it in my city, I can’t find it, and in principle, there’s nothing to it. 
Industrial machines are certainly good, but I will probably use them for a couple of months and abandon this occupation, and in general, such a machine, as I found out, can be easily assembled by myself from plywood and wooden bars.
The next photo uses an industrial manual jigsaw and a spring to return the file.
So, we can easily assemble a desktop jigsaw with our own hands at home. I personally did this, but I have a special design, there are no photos of me in this article, but I will definitely post it, as well as a video in work.
- Manufacturers, models
- JET JSS-16
- JET JSS-16e
- Kraton WMSS-11-01
- Holzstar DKS 501 Vario
- Scheppach SD1600V
- Scheppach Deco Flex
- PRORAB 4000
- Proxxon DS 460
- Hegner Multicut-2S
With the help of a jigsaw tool, various Construction Materials, form curly parts used in carpentry shops when assembling furniture.
Manufacturers, models
Most often, desktop jigsaws of the brands Bosch, Makita, JET, DeWALT, Corvette, Proxxon, Excalibur, Zubr are used. The equipment demonstrates stable operation, good performance. So, electric jigsaw The new Bosch machine has a long operating period and is of high build quality. DeWALT equipment is characterized by smooth, uninterrupted operation. The desktop jigsaw "Zubr" is equipped with an adjustable pendulum stroke of the saw, which improves the quality of the cut surface.
Stationary electric jigsaw machine Encore Corvette copes with oblique, longitudinal, transverse cuts. The German Einhell desktop electric unit is sold in 53 countries around the world. Jigsaw Dremel machines("Dremel") are equipped with a wide range of saw blades, with which you can make parts of complex configuration.
When choosing, you need to study the features of the equipment, know for what purposes an electric jigsaw is purchased, how often it will be used.
JET JSS-16 (10,560 rubles)
The JET desktop jigsaw is used in home workshops, small carpentry workshops for curvilinear cuts of the workpiece. It is possible to install saws with various fastening. Stroke frequency range adjustable from 400-1600 strokes per minute. This ensures high-quality processing of plastic, plywood, chipboard, natural wood.
JET JSS-16e (12,320 rubles)
Jigsaw machine with asynchronous motor copes with straight and radius sawing of wood of various hardness, polymeric materials. Operating speeds - 400-1800 passes per minute. Safety guaranteed by the transparent cover, the sawdust fan keeps the work area clean.
Kraton WMSS-11-01 (5 679 rubles)
The machine is designed for forming decorative parts from wood, sawing wood in the longitudinal, transverse direction, along an inclined line. The desktop can change the angle of inclination, cutting file installed in two positions. At desktop jigsaw large frame overhang, so dimensional workpieces can be processed on it.
Holzstar DKS 501 Vario (8,700 rubles)
The desktop jigsaw is designed for cutting external and internal contours of various configurations, including complex curvilinear figures. It is also used for cutting parts made of soft woods, plastic bases. The cutting line is cleaned by an adjustable wood dust removal system. Possibility of connection of the vacuum cleaner is provided.
Scheppach SD1600V (9 800 rub.)
Distinctive characteristics of machines - low level vibration, stable sawing of parts from various materials. You can choose the angle of the desktop depending on the nature of the work. The compactness of the equipment allows it to be used in small workshops, at home.
Scheppach Deco Flex (13,975 rubles)
The sample is equipped with a flexible shaft, which ensures the finishing of lumber. With its help, complex furniture elements are cut out. The stroke speed is adjustable in the range of 550-1650 rpm, the cutting depth is 500-405 mm.
PRORAB 4000 (6 825 rubles)
Desktop jigsaws cope with sawing wood, plastic, metal blanks. Differ in high stability: have the wide basic basis. The working element cooling system prevents the saw from overheating due to friction.
Proxxon DS 460 (34,500 rubles)
The jigsaw unit is equipped with a stable cast steel construction and a magnesium rocker arm. To replace the cutting element, the aluminum table moves 8 cm horizontally. The saws with pin and flat ends can be installed on the machine, providing a high-quality cut of wood, plastic, metal, plexiglass.
Hegner Multicut-2S (52,720 rubles)
The professional electric jigsaw is easy to operate and clean cut. The unit is completed with a set of original saws capable of cutting wood, polymeric materials, metal blanks. Optionally, the model of machines is supplemented with a speed controller, while the cost increases.
The table shows the characteristics of the models trademark"Bison" and jigsaws "Corvette".
|
Power, W |
Number of strokes/min |
Wood cutting depth/mm |
Price, rub. |
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Bison ZSL-90 |
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Bison ZSL-250 |
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A very nimble and compact enough tool, it can be incredibly useful for cutting straight and curly shapes. Appearance and the functionality of the sold jigsaws is impressive, making you believe in the incredible complexity of the design of these devices. In fact, to recreate such a mechanism, it is enough to understand the principle of its operation, have instructions and a desire to do something with your own hands. It is not necessary to be an expert in technology with years of experience(although this quality will not be superfluous). Next, we will conduct a detailed analysis of the average jigsaw model with drawings, and provide two detailed guides By self-manufacturing similar tool.
How an electric jigsaw works
Although the jigsaw device is not particularly complex, its mechanism has certain features that require familiarization. To understand how to make a jigsaw, you must first understand what makes the saw blade reciprocate. For the most clear idea of the principle of operation of the device, we will present the main components that make up the mechanism of the tool and describe their interaction with each other.At the heart of any electric jigsaw are the following components: an electric motor, a gearbox and a rod with a saw blade clamp. Secondary but no less important elements include the start button, the support roller, the cooling fan and the soleplate. As additional functionality, many models have a pendulum stroke, a dust collector, a backlight and a laser guide. We will not touch on the principle of operation of the latter, and proceed to a description of the interaction of the main elements of the mechanism.
The high-frequency movements of the jigsaw saw blade originate from the electric motor, which is started by pressing a button or directly from the mains. The rotation is transmitted along the shaft to a special “reducer” mechanism with an eccentric, which interacts with the rod, forming reciprocating movements. In the mount, installed at the end of the rod, the saw is fixed, making the cut. To minimize the load on the rod with the gearbox, the rear edge of the saw blade rests against the support roller. Thus, all components of the device are involved in order to perform main task for sawing all kinds of materials.
Drawings of electric balls
A detailed study of any device is much easier when there is detailed diagram with a description of each element. Thanks to the exact names of parts with dimensions, the general idea of the principle of operation of the mechanism becomes more visual. Below we have posted a few detailed illustrations, since it is much easier to assemble an electric jigsaw with detailed drawings than to rely only on your own idea of the design features.
We hope that the presented diagrams will completely clarify your understanding of the structure of such a mechanism and give healthy food for reflection in assembling your own jigsaw.
Making a jigsaw with your own hands
For a craftsman who understands the principle of operation of any mechanism, it will not be great work reproduce it, especially if you have detailed instructions. The bicycle has already been invented, and to make it yourself, it is enough to have a set necessary details and tools. The guide below will demonstrate in detail how to make a jigsaw with a complete listing of the elements and tools required for the job. The created product is not a stationary device, but a mobile saw with an electric drive. The power in the device is not so much, but enough to cut wood, up to 5 mm thick.
Required materials:
- Wooden block - 150x75x25 and 75x25x25 (width, height, thickness in mm)
- Metal plates - long and rectangular (as in the photo)
- Electric jigsaw file with U-shank
- Electric motor RS-540 12V (you can use any similar one)
- Electric circuit closing button
- Nozzle gas stove
- Bicycle spoke
- Plastic circle with a diameter of 260 mm
- Plywood - 120x50x5
- Set of screws, bolts and nuts
- Hacksaw for metal
- triangular file
- Pliers (2 pcs)
- Screwdriver or drill with a set of drills
- Metal shears
- Pencil
The assembly of the jigsaw will begin with sawing out the handle from a larger bar. To do this, it is enough to cut, giving a rectangular board L-shape as in the photo. The dimensions of the sawn part are set "by eye", based on the preferences and size of the operator's hand.
One of the most important nodes a device that serves as a movable rod and a saw blade retainer requires increased reliability. This element is made of a long metal strip, 1 mm thick. At the end, the outline of the file shank is outlined, after which a triangular file is filed to create a pressure plate. Part of the metal strip is bent with pliers along the contour of the shank, after which a file is installed in an impromptu mount and drilled through hole for additional fixation with a bolt.
The saw blade, fixed on the rod, must be connected to the device using a guide. This part is made of rectangular metal plates. With the help of pliers, we bend the center of the plate into a flat groove for the stem with side mounting lugs. To prevent abrasion of wood and facilitate the movement of the file, we apply a similar piece of metal to the front side of the prepared handle and twist it together with the groove. As a result, the following construction should be obtained.
At the end of the rod, carefully bend the metal until a kind of loop is obtained, into which the end of the lever of the crank mechanism will be inserted.
We fasten the previously sawn off wooden rectangle to the top. It will serve as a stand for the motor, creating extra space for installing crank elements.
The transformation of engine rotations into reciprocating movements will occur with the help of an elementary mechanism made of a round plate, a gas nozzle and a weight-bearing spoke. In the center of the circle, we drill a hole with a diameter equal to the threaded part of the nozzle (so that it fits as tightly as possible). Next, install the nozzle in place and fix with epoxy resin. We put the dried structure on the motor shaft. If the nozzle hole is too narrow, you can expand it with a drill of the required diameter. Between the center and the edge of the circle, we drill another small hole with the diameter of a bicycle spoke.
Unfortunately, not everywhere you can find an upgraded gas stove nozzle with a side screw used in the instructions. If only an ordinary one is available, it can be fixed on the shaft with a tin and a soldering iron, as in the photo below.
Having combined the engine with a round plate, it's time to turn it into a real crank. To do this, we take a bicycle knitting needle and bite off the bent hat and the threaded part with pliers to get an even metal rod. Next, we retreat from one end 10 mm, and bend at an angle of 90 °. We insert the bent part into the previously prepared eyelet in the stem and lift it up so that the screw for fixing the file rests against the metal plate.
The accuracy of the next step is most important, since the amplitude of the movement of the saw blade depends on it. It is necessary to determine the exact place for making the second bend of the rod so that the crank and rod connected by it work most efficiently. To do this, we put the engine in place of the future mounting and place the extreme hole of the circle up. Next, we bring a rod to the hole, the opposite edge of which is inserted into the eye of the rod raised to the stop and mark the place of the bend. We make a bend at an angle of 90 °, insert it into the hole of the circle and check the operation of the mechanism. If the crank works as it should, fix the motor in place with a metal plate.
The next structural element will be the sole, which also acts as a support for the saw blade. You can make a similar part from ordinary plywood, 5 mm thick. In the center of one of the ends, we make a small cut (20-30 mm) and pass the file of our jigsaw into it. We fix with a self-tapping screw with a countersunk head.
The final step is to install the start button and connect the wires. The button can be displayed in any place convenient for you. The author considered it necessary to put it on hot glue in the corner of the handle. We create an elementary electrical circuit(motor-button-network and motor-network) and connect to a 12 volt power supply.
For smoother running, it is recommended to lubricate the stem with oil.
A more visual demonstration of this instruction, but unfortunately without comments, can be viewed in the video below.
Homemade jigsaw for polystyrene
Assembly of a fairly convenient and reliable device for cutting thin wooden blanks and polystyrene. This method is almost similar to the previous one, but has a more functional design. Compose detailed description how to make this electric jigsaw with your own hands is not necessary, since the design of the device is similar to the previous assembly. We will bring full list necessary materials and manufacturing tools.
- Plywood 200x200x5 mm
- Wooden block - 120x50x50
- Spatula or sheet of metal, 1 mm thick
- Metal terminal for connecting wires
- Metal rod (spoke)
- Hacksaw blade
- Electric motor (DC) at 12 volts
- A piece of thin, flexible plastic
- Mounting metal corner
- A piece of PVC pipe as a handle
- Contact closure button
- 12 volt power supply with DC plug
- DC power connector
- Self-tapping screws, bolts and nuts
By instruments:
- File (file)
- Metal shears
- pliers
- Drill or screwdriver with a set of drill bits
- Core drill for wood with a diameter of 44 mm
- soldering iron
- Thermal gun
Also, there is another option homemade jigsaw. The principle of operation of this product is similar to the previous two, there are some nuances in the design. We hope that the following video will be useful and give you fresh ideas for creating your instrument.
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A desktop jigsaw is useful for every craftsman who cuts out thin details. However, it is far from always possible and meaningful to acquire a full-fledged machine. In this case, get down to business and do it yourself!
The device of the jigsaw machine - what lies inside?
Jigsaw machines are more about special tools than about devices that are needed as experienced master, and the amateur hosting in the garage. Their purpose is reduced to a special task, namely, cutting out complex curvilinear contours from sheet materials. A special “chip” of such machines can also be attributed to the execution of the cut without violating the integrity of the external contour. Most often, sawing occurs on wood and derived materials (plywood, chipboard, fiberboard), although modern machines equipped with appropriate nail files are able to work with other materials, such as plastic or drywall.
Such equipment has found application in the music industry (manufacturing musical instruments) and, of course, in furniture. They buy such units and lovers of tinkering in their own workshop. The device of a traditional jigsaw machine, designed according to all the rules, is as follows: working surface, on which the saw is brought out, hides the drive (electric motor) and the crank structure under it. The tension mechanism can be located both below and above the machine.
To process a part, it must be placed on the desktop. Many models have the ability to rotate it at different angles to make bevel cuts. Stops and guides on the surface, as well as rotary mechanism can have markup, which greatly simplifies and speeds up the work. It is the length of the cut that depends on the length of the desktop - most models are limited to 30-40 cm. The power of the electric motor is an important, but still far from the most fundamental factor, since the machine has a huge margin of unclaimed power. For example, for a home workshop or even a small production, a “engine” of only 150 watts is enough.
Crank mechanism - much more important detail, because in this case it depends on it the quality of the transfer of the torque of the drive into the forward-return motion directed to vertical plane by means of a saw.
Standard jigsaw machines are considered devices with a range of motion in the region of 3-5 cm at an oscillation frequency of up to 1000 per minute. In many models, a change in speed mode is provided for different materials. The jigsaw itself is usually made up to 35 cm long and is able to cut material up to 10 cm thick. The width of the files can vary in a fairly wide range - from very thin two-millimeter to coarser ten-millimeter, with a thickness of 0.6 mm to 1.25 mm.
Even the thickest and widest nail file will easily break if you do not provide sufficient tension along the entire length of the nail file. For this, spring and helical springs are used. Quite often, such machines are equipped with air pump, which cleans the cut from sawdust by blowing, as well as a drilling block. The last device is especially useful, because in this case, the master does not need to be distracted by the connection electric drill and drilling a hole - everything happens on the working plane of the machine. Of course, you have to pay for convenience!
How to make a jigsaw machine with your own hands from a manual jigsaw?
On the web you will find many different designs homemade machines, but most of them come down to reprofiling into this machine. Using your ingenuity and watching the video, you can easily make a homemade jigsaw machine from this tool. You only need to modify the jigsaw a little. In fact, it plays the role of a machine tool drive and a crank mechanism, the rest needs to be thought out and implemented.
Of course, manufacturers are trying to please consumers in this area as well, offering their own platform options for quick and convenient rework, however, in reality, only you can make an apparatus that meets your needs. So, the first step is to make a support table, for which they most often use sheet metal. In it you need to make a slanted oblong hole for the saw blade and holes for fasteners (countersunk screws are recommended), and attach the jigsaw to the bottom of the support table.
This design remains only to strengthen on wooden table. You can go beyond this and install guide rails. The convenience of such an apparatus lies in the fact that in addition to performing functions that are not entirely inherent in it, you can always disconnect the drive and with a flick of the wrist turn it back into a manual electric jigsaw! If you constantly need this tool for work, it makes sense specifically for the machine - it will be cheaper than spending money on a real machine.
Advantages and disadvantages - we continue to modify!
But such an assembly inherits not only the advantages of the tool, but also its disadvantages, in particular, a nail file that is too wide for filigree work, which significantly limits the curvature of the lines. If there is a need for this, there is a way out. So far, our machine differs from the classic jigsaw unit by the absence of springs that would provide sufficient tension for the nail file. But to build a simple rocker, which on the one hand will be under the tension of the springs, and on the other hand fixed on a nail file, is quite easy.
There is another option - to clamp the nail file between two guide rollers, but the first option is still more reliable. Do not forget to turn off the pendulum stroke on the jigsaw before you start using a homemade machine. There is another design - if your tool is powerful enough, then it can only serve as a drive in a design of two rocker arms, between which a nail file is stretched. The movement is transmitted by means of a nail file fixed on the lower rocker arm.
Machine from a sewing machine - we give a second life to old tools!
If you inherited from your grandmother or mother got a foot or hand sewing machine, consider yourself the owner of an excellent jigsaw machine! Of course, for this you need to “conjure” a little over the machine. First, remove the thread weaving device, which is usually located at the bottom of the machine. There is nothing complicated in this, it is enough to unscrew the two bolts. Then we knock out the cotter pin and remove the drive shaft leading to the thread weaving mechanism.
Having unscrewed the top panel that protects the mechanisms, it is necessary to expand the slot in which the needle went. Focus on the needs and width of the nail file that you will use in your work. Jigsaw blades of this kind also need to be slightly modified, namely cut to the maximum length of the needle that could be used on this machine. After grinding off the upper teeth and sharpening the lower part on the point, you just have to insert the nail file into the needle holder and test your machine in action!
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In this article, as I promised in previous posts, we will talk about one more homemade device for the work of craftsmen.
At the heart of this device, as you can see in the photo, is an ordinary electric jigsaw.
I believe that the jigsaw, like the grinder, is very universal tools, which, when changing nozzles, whether it be a nail file or a cutting disc, can be used in different operations.
I made this device as an alternative to a manual circular electric saw, which, of course, failed at the most inopportune moment.
And I want to say that even after the repair of the circular saw, I still continued to use the jigsaw machine in my work.
Of course, an electric jigsaw is much inferior to an electric saw in the speed of cutting parts. But he has an advantage - this is a curvilinear cut.
And it seems to me that a jigsaw is safer than a circular saw.
In short, we do jigsaw machine.
To make, you will need material:
- Dural strip 930 × 310 mm in size, 2 mm thick.
Plexiglas (10 mm) can be used, but it is more difficult to bend.
- Aluminum corners sizes:
15×15 mm, length 375 mm - 2 pcs.
20 × 20 mm, 60 mm long - 4 pcs.
40×40 mm length 130 mm - 1 pc.
- Bracket-bracket size 85×20×2 mm - 1 pc.
- Metal plates measuring 45 × 14 mm - 2 pcs.
I used furniture awnings, because. they were just the first ones that came to my hand, so if you use any other plates, then it's okay.
- Plywood 300×290 mm thick not thinner than 10 mm.
You can use plywood 20 mm thick, but then you will need to use a jigsaw file longer than usual, for example, 126 mm.
Accessories:
- Screw М5×30 – 1 pc.
- Screw М5×50 – 2 pcs.
- Screw with nut М6×20 – 1 pc.
- Screw with nut М4×16 – 1 pc.
- Self-tapping screws 3.5 × 16 - 20 pcs.
- Self-tapping screws with a drill 3.5 × 9.5 (fleas) - 14 pcs.
- Self-tapping screws with a press washer 4 × 16 - 2 pcs.
Also, for work you will need not a large arsenal. tool.
- Drill with a set of drills.
- Bulgarian with a cutting wheel for metal.
note
that duralumin is cut with a special disc cutter With small tooth from victorious.
But I did not buy such a cutter, because. I do not process sheet duralumin, but only cut aluminum profile For .
- Jigsaw.
- Screwdriver.
The procedure for manufacturing a machine from an electric jigsaw
✓ Cut off a duralumin strip 930 × 310 mm in size with a grinder.
note
to make it easier to cut, it is necessary to use cutting wheel for metal with such parameters 125×1.0×22 mm. Where the size of 125 mm can vary depending on the grinder itself (angle grinder).
Main so that the thickness of the cutting disc is no more than 1.2 mm!
✓ We measure from the left and right edges 300 mm of the bend line.
✓ We bend each side separately at an angle slightly less than 90 °.
This is necessary for better stability of the entire structure.
✓Cut off the grinder two aluminum corner 15x15mm 375mm long and four 20x20mm corners 60mm long.
✓ Using fleas, we connect the corners 20 × 20 mm with the side ones at a height of 40 mm from below.
✓ We attach corners 15 × 15 mm 375 mm long to them with fleas.
This gives the product rigidity.
✓ We cut plywood 300 × 290 mm with a jigsaw for the substrate to the table.
✓ We connect it to the duralumin base using self-tapping screws (3.5 × 16 mm) in twenty places.
All the frame is ready.
✓ Turn it over with plywood to the top.
✓ We make markings for a through slot for a file.
✓ We cut through the grinder.
✓ Insert a jigsaw and mark the holes for attaching the sole to the table.
✓Drill with a ø5 mm drill.
Advice.
The diameter of the hole should be equal to the diameter of the thread on the base of the jigsaw.
ø5 mm=M5.
This is necessary for a tighter connection.
✓ We attach the jigsaw with three M5 screws to the table.
Now you need to make a guide support for the jigsaw file.
To do this, I used a ceiling lamp mounting bracket from a floor lamp and two plates from
furniture awnings.
✓ We measure 85 mm from the file and make a cut with a grinder with a length and thickness equal to the size of the inserted corner.
note, after marking the jigsaw must be removed!
✓ Insert the corner into the slot and fix it with screws with a press washer to the plywood.
✓ We attach to it with fleas the bracket assembly with the guide plates for the file.
All the jigsaw machine is ready.
The main advantage of such a device– these are metal saw guides that maintain an absolutely flat vertical (90°) during operation!
Many craftsmen know that almost all electric jigsaws have a significant drawback; when sawing a part, the vertical of the saw is broken. If you look at the end, the file goes at a slight slope. And this slope can change in different directions throughout the entire length of the cut.
Well, another plus of this product is that it is not heavy and small-sized.
Flaws:
- When working, you have to hold your foot.
- I did not make a separate button for on and off.
- You can’t saw thick bars or boards, but I don’t need it, because. I am thicker than chipboard (16-18 mm) and do not dissolve anything.
Wooden or MDF lining or - easier than ever!
And, if you put a diamond-coated file for ceramics, then you can tile cut.
Of course, this sawing machine from a jigsaw, as I did from what came to my hand, so it’s not at all necessary to use just such materials. You can experiment with other materials.
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